IYETU
BARILOGI

A 3000+ asset industrial facility had no structured maintenance system. Work orders were logged on paper, equipment history was non-existent, and 85% of maintenance was reactive. Planners had no visibility into backlog or resource demand.

Led full CMMS implementation: developed asset hierarchy (location → system → equipment), created equipment numbering conventions with smart tagging, built 500+ PM tasks with OEM-aligned intervals, and configured work order workflow from creation to close-out.

PM compliance reached 80% within 6 months. Reactive maintenance dropped from 85% to under 35%, reducing unplanned downtime exposure and improving production stability. Maintenance backlog became measurable. Team shifted from daily firefighting to weekly structured planning cycles.

Maintenance backlog had grown to 6+ weeks of uncompleted work orders. No prioritisation logic existed. All requests were treated equally, regardless of safety or production impact. Technicians were pulled from planned work to attend emergencies daily.

Introduced a work order prioritisation matrix (Safety → Production Impact → Regulatory → Routine). Restructured weekly planning meetings using CMMS backlog reports. Implemented a 4-week rolling schedule separating planned from reactive responses.

Backlog reduced from 6 weeks to under 2 weeks within one quarter. Unplanned work interruptions decreased by 50%. More than 60% of work was scheduled rather than demanded. Supervisor confidence in weekly planning improved measurably.

Three critical pump systems were failing every 4–6 weeks, each failure causing 8–14 hours of production downtime. The root cause was treated each time as an isolated event. No failure data was being retained or analysed systematically.

Extracted work order history from CMMS and built failure frequency analysis. Conducted structured RCA sessions for the three worst-performing assets. Identified lubrication intervals and alignment tolerances as core contributors. Revised PM tasks and introduced condition monitoring checkpoints.

Mean time between failures increased from 5 weeks to over 22 weeks. Annualised downtime on those assets reduced by ~120 hours. The structured failure tracking process was subsequently adopted for the top 15 critical assets facility-wide.